Paper-forming suction cylinder roll with arcuate stock delivery nozzle and porous belt in wrapped engagement therewith



Oct. 14, 1969 s. G. Hou' PAPER-FORMING SUCTION CYLINDER ROLL WITHARCUATE STOCK DELIVERY NOZZLE AND POROUS BELT IN WRAPPED ENGAGEMENTTHEREWITH Filed April 18. 196s United States Patent O IAPER-FORMINGSUCTION CYLINDER ROLL WETH ARCUATE STOCK DELIVERY NOZZLE AND POROUS BELTIN WRAPPED ENGAGE- MENT THEREWITH Sherwood G. Holt, Wisconsin Rapids,Wis., assignor to Consolidated Papers, Inc., Wisconsin Rapids, Wis., acorporation of Wisconsin Filed Apr. 18, 1966, Ser. No. 543,268 A Int.Cl. D21f 1/60 U.S. Cl. 162-301 12 Claims ABSTRACT OF THE DISCLOSURE Apaper making machine including a stock nozzle the upper lip of which isarcuate with a rotatable suction forming cylinder and defines a firstforming zone, and an endless flexible stock control member which ispartially held in wrapped engagement with the cylinder periphery to forma second forming zone with dewatering means thereover.

The present invention relates to paper-forming apparatus, andparticularly to apparatus which utilizes a cellular suction formingcylinder or roll to form a continuous paper web from liquid stocksuspension or furnish delivered to the periphery of the roll for anozzle.

It is known to provide a cellular suction forming roll in place of theextremely long Fourdrinier section conventionally used in paper-makingmachines. Such a suction forming roll comprises a rotatable cylindricalshell having a plurality of radial openings therein. A nozzle isemployed to supply the stock suspension to a predetermined forming areaon the surface of the rotating suction roll, and the major part of thewater in the stock suspension is removed by suction means disposedinside of the forming roll, such water being largely dischargedoutwardly from the forming roll by centrifugal force after the portionof the roll containing the water has passed beyond the forming area andbeyond the effect of the vacuum section within the roll. In this manner,a continuous web of paper is formed on a Fourdrinier wire on the surfaceof the suction forming roll and is subsequently removed by a suctionpick-up or couch roll over which a pick-up felt is trained. One type ofcylinder sheet forming apparatus is shown in Ostertag et al. Patent2,418,600 wherein a traveling Fourdrinier wire is trained over a suctionforming roll and the stock suspension is delivered to the wire at anarea where the latter is directly supported by the forming roll. Anothertype of cylinder sheet forming apparatus is disclosed in my copendingapplication Ser. No. 315,033, filed Oct. 9, 1963, now Patent No.3,321,360, and assigned to the assignee of the present invention. In mycopending application there is described a suction forming rollincluding a Fourdrinier wire in the form of a sleeve which is intimatelyengaged over the periphery of the roll.

One of the major problems which has been encountered in the use ofcylinder forming devices of the type described hereinabove has beencaused by the nozzle for delivering the stock suspension to theperiphery of the forming roll. Thus, in order to have the stock undercomplete control until the paper web is formed or set, it has beennecessary to provide an upper nozzle lip which extends for severalinches over the periphery of the forming roll and has a tip which isdisposed in extremely close proximity to the forming roll wire surface.The clearance between the metal tip of the upper nozzle lip and theforming roll wire surface has usually been between 0.010 inch and 0.040inch. Due to su-ch close proximity of the metal nozzle tip to thesurface of the Fourdrinier wire,

'ice

there has been a serious problem created due to the possibility thatsmall pieces of hard material flowing through with the stock suspensionwill be caught under the tip and cause damage to the Fourdrinier wire.While careful screening of the stock suspension may tend to reduce sucha problem, it has nevertheless been one of the major shortcomings of thecylindrical suction forming roll.

It is therefore an object of the present invention to provide improvedsheet-forming apparatus including a cylindrical forming member where theabove-des-cribed difficulty caused by small pieces of hard material inthe stock suspension is substantially eliminated.

It is a further and important object of the invention to providepaper-forming apparatus as last abovementioned which permits formationof a high quality continuous paper web at unusually high speeds and withrelatively simple and inexpensive equipment.

The foregoing and other objects and advantages of theinvention will beapparent from the following description thereof.

Now in order to acquaint those skilled in the art with the manner ofpracticing and utilizing my invention, I shall describe, in conjunctionwith the accompanying drawings, certain preferred embodiments of theinvention.

In the drawings:

FIG. 1 is a side elevational view, partly broken away, illustrating acylindrical paper-forming device constructed in accordance with thepresent invention; and

FIGURE 2 is a fragmentary side elevational view illustrating analternative form of suction apparatus for dewatering from the top sideof a continuous paper web being formed on the cylindrical forming rollof FIG- URE l.

Referring now to the drawings, there is shown a rotatably mountedcylindrical suction forming roll indicated generally at 1t) comprising acylindrical shell 12 having a plurality of closely spaced radial holesor cells 14 formed therein. A plurality of circumferentially spacedlongitudinal spacer strips 16 extend along the outside of thecylindrical shell 12 and support a foraminous surfacing material or thelike (not shown in detail) over which a wire sleeve 18 is mounted. Ifdesired, a traveling Fourdrinier wire could be trained over the lformingroll 10 as shown in the above-mentioned Ostertag et al. patent, but itis preferred that the wire comprise a sleeve which thus constitutes theperipheral surface of the forming roll.

Within the rotatable cylindrical shell .12 there is positioned astationary tubular member 20 which together with a pair of radialpartition walls 22 and 24 defines a pressure diiferential controllingbox assembly or chamber to assist in and control the rate of thedewatering of the stock suspension which is supplied to the wire surface18 of the suction Iforming roll. The hollow member 20 need not of coursebe tubular, and may be of any desired configuration. The radialpartitions 22 and 24 extend the full length of the forming roll 10 andare provided at their radially outer ends with sealing strips 26 and 28.Additional partition walls 30 and 32 having sealing strips 34 and 36 mayalso be provided, the latter partitions being circumferentiallyadjustable and serving to divide the pressure diiferential controlilngchamber in several compartments which may be subjected to varyingpressures as desired, Stich pressures normally being below atmosphericpressures. For a more detailed description of the cellular lsuctionforming roll 10, reference is made to my earlier-mentioned copendingapplication Ser. No. 315,033, now Patent No. 3,321,360.

A nozzle assembly 40 comprises a nozzle 42 and associated supportingframework 44. The nozzle assembly 40 is pivotally mounted on a pair oftrunnions, one of which is shown at 46, the trunnions 46 in turn beingsupported on a stationary frame (not shown). The nozzle assembly issupported and held in a predetermined pivotal position by means of jacks(not shown) which extend between the movable `framework 44 and the fixedframe member, such jacks being adjustable to control the spacing betweenthe nozzle lips and the periphery of the suction forming roll 10. Thenozzle 42 comprises adjustable upper lip sections 48a and 48b, and afixed lower lip 50, there being also shown a nozzle inlet 52 and anozzle throat portion 54.

A pair of jacks 56 and 58 each have one end connected to the nozzleframework 44 and their other ends connected to lugs 60 and 62respectively on the adjacent pivotal sections 48a and 48b of the uppernozzle lip, whereby through adjustment of the jacks 56 and 58 theposition of the upper nozzle lip sections 48 relative to the lower lip50 and the forming roll 10 may be accurately adjusted. The stock nozzle42 is supplied at its inlet 52 with stock suspension through the usualsupply pipes and through transition pieces which spread out the flowinto a wide thin pattern of uniform dimensions and density acrosssubstantially the entire axial length of the roll 10. The nozzle inlet52 converges or tapers inwardly somewhat so as to maintain the stocksuspension under pressure and complete the flow transition, and it feedsthe stock suspension to the nozzle throat portion 54 from which it isdelivered to the wire surface 18 on the forming roll. The foregoingnozzle assembly 40 is also described in greater detail in my copendingapplication Ser. No. 315,033, now Patent No. 3,321,360.

It is an important `feature of the present invention that the uppernozzle lip section 48a is relatively short, and a stock control memberin the form of a movable top wire or fabric is provided to functionsomewhat as an intension of the nozzle lip and thereby control the stockduring formation of the continuous paper web. Thus, there is shown a topwire assembly 64 including a supporting frame 66 comprised ofinterconnected frame elements 68, 70 and 72, the frame 66 being pivotalabout a pair of trunnion shafts such as shown at 74. The pivotalposition of the frame 66 on the trunnions 74 is determined by one ormore adjustable jacks 76 which extend between the upper end of the frameelement 68 and a fixed support beam 78, the latter including a lug 80for connection with the jack member.

A plurality of rolls of pulleys are rotatably mounted on the supportingframe 66 in order to support and drive an endless fabric or wire stockcontrol member 82 which is trained over a portion of the periphery ofthe forming drum adjacent the end of the upper nozzle lip section 48aand thereby controls the stock during formation of the continuous paperweb. Thus, a drive roll 84 is rotatably mounted on a shaft 86 supportedby bearings 88 extending from the lower end of the frame element 68. Thedrive roll 84 engages the outside of the endless wire 82, and the roll84 is driven by a variable speed motor (not shown) so as to drive thewire 82 at a desired speed, preferably at approximately the same speedas the peripheral speed of the forming roll 10. A wire turning orsupport roll 90 is rotatably mounted on a shaft 92 supported in bearings94 which also project from the lower end of the frame element 68, andthe roll 90 engages against the inside of the endless wire 82 to supportthe same. Above the support roll 90 there is mounted a wire turning orsupport roll 96 which is rotatable on a shaft 98, the latter beingsupported on a carriage 100 which is slidable along one or more guiderods 102. The support roll 96 is engaged against the inside of theendless top wire 82, and the carriage or slide 100 may be adjustablypositioned on the guide rods 102 in order to apply a predetermineddesired tension to the wire.

A pivotally mounted arm 104 serves to support one end of a shaft 106 onwhich an adjustable wire control roll or guide roll 108 is rotatablymounted. The other end of the shaft 106 is mounted in a universalspherical bearing or the like (not shown), and the pivot arm 104 has oneend pivotally mounted to a bearing 110 by means of a pin 112, thebearing 110 being fixed to the frame element 70. Accordingly, movementof the arm or lever 104 about its pivot pin 112 will cause the rollershaft 106 to pivot about the one end thereof which is universallymounted. An air cylinder 114 has one end connected to the arm 104 at116, and its other end connected to a lug 118 supported near the upperend of the frame element 68, and a tension spring 119 extends betweenthe arm 104 and the frame element 72. Thus, by controlling the pressureof the air supplied to the air cylinder 114, and thereby varying theextension of such air cylinder and of the coacting spring 119, it ispossible to vary the position of the arm 104 and in this manner controlthe orientation of the shaft 106 and wire control or guide roller 108.

The guide roller 108 engages against the outside of the endless stockcontrol member or wire 82, and the position of the roll 108 iscontinuously adjusted as required by means of the air cylinder 114 inorder to control or guide the movement of the stock control member 82.More specifically, a movable feeler or sensing member (not shown)engages the moving stock control member 82 and senses lateral ortransverse movements of the latter. The feeler or sensing member isassociated with valve means (not shown) so as to control the pressure ofthe air supplied to the air cylinder 114 in accordance with the lateralposition of the stock control member relative to the roll 108. Thus,whenever the stock control member 82 tends to move from a centeredposition on the roll 108, the orientation of the roll is varied in orderto maintain the member 82 in a centered position on the roll. In thismanner, as is known in the art, the moving endless stock control memberor wire 82 is continuously maintained in a proper centered position onthe roll 108 and on the various other support rolls over which ittravels.

Reference is now made to a pair of adjustable wire turning or supportrolls 120 and 122 which are supported from the lower frame element 72 inclose proximity to the periphery of the forming roll 10 in order tocause the stock control member or endless wire 82 to partially wrap orengage on a portion of the forming roll wire surface 18. The supportroll 120 is rotatably mounted on a shaft 124 supported by a pair ofbearings 126 which project downwardly from a mounting bracket 128. Themounting bracket 128 is secured to one end of the frame element 72 andits position may be adjusted toward or away from the forming roll 10 byloosening the nuts 130 and varying the position of the threaded stop pin132. The wire turning or support roll 122 is rotatable on a shaft 134supported on bearing blocks 136 depending from the underside of theframe element 72 and the rotatable support roll 122 is disposed in closeproximity to the forming drum 10 and to the end of the upper nozzle lipmember 48a. At the end of the upper nozzle lip element 48a the topsurface thereof is generally arcuate as shown at 138 so as to conformapproximately to the configuration of the roll 122. The roll 122 ispositioned quite close to the arcuate upper surface 138 of the nozzlelip, and in this manner it locates the endless wire 82 so that thelatter runs through a narrow slot between the roll 122 and the top lip48a and constitutes an approximate extension of the upper nozzle lip.The right hand support roll 122 is preferably mounted so as to beadjustable toward and away from the left hand support roll 120. Due tothe adjustability of the two wire turning or support rolls 120 and 122,it is possible to effect variable pressing or convergence of the paperweb between the forming roll 10 and the endless top wire or fabric 82.

It will be understood from the foregoing that `the drive roll 84, theseveral turning or support rolls 90, 96, 108, 120 and 122, and theendless stock control member or wire 82, all extend for substantiallythe full length of the suction forming roll 10, and the portion of theendless wire 82 between the two turning rolls 120 and 122 is heldagainst a portion of the sheet being formed on the wire surface 18 ofthe forming roll 10 so as to control the paper web being formed thereonfrom the stock suspension supplied by lthe nozzle `42. The variablespeed drive roll 84 is preferably driven so as to drive the wire 82 atthe peripheral speed of the forming roll 10. The pivotal position of theentire top wire assembly 64 relative to the pivot shaft 74 is controlledby the jacks 76 and also by a threaded adjustable stop member 140 whichis mounted on the frame element 68 and is engageable against a fixedframe element 142. As previously stated, the wire turning roll 120 isadjustable toward and away from the forming roll 10, and the wireturning roll 122 is preferably adjustable in a transverse directiontoward and away from the turning roll 120. After the paper web is formedon the wire surface 18 of the suction forming roll 10, the web iscouched off of the forming roll by a pick-up felt 144 which is trainedover a pick-up roll 146 and a support roll 148.

As stated earlier herein, and as described more fully in my copendingapplication Ser. No. 315,033, now Patent No. 3,321,360, the suctionforming roll effects dewatering of the stock suspension and resultingpaper web due -to the suction applied at the wire side or bottom side ofthe web. However, in accordance with the present invention it ispossible to effect additional dewatering through utilization of suctionmeans or foils or the like which act upon the felt side or -top side ofthe web. For example, in the embodiment shown in FIGURE l there isprovided a suction or vacuum box indicated generally at 150 andcomprising a top Wall 152, longitudinal side walls 154 and 156, yand apair of rolls 158 and 160 which are in a sealing relationship with thelongitudinal side walls 154 and 156 and in engagement with the topsurface of that portion of the endless wire 82 which is partiallywrapped on the periphery of the forming roll 10. The suction box 150 isconnected at 162 to a vacuum source, :and the suction box is supportedon the lower frame element 72 and is adjustable thereon toward and awayfrom the forming roll 10. In this manner, the paper web being formed -onthe forming roll 10 may be dewatered not only from the wire side by thesuction means within the forming roll, but also from the top or feltside of the web by means of the suction box 150 which withdraws thewater moving up through the wire 82.

FIGURE 2 shows an alternative embodiment of the invention includingapparatus 170, comprising one or the other and preferably both of anarrow suction lip or doctor and a scraper foil for the top wire orfabric, which may if desired be substituted for the vacuum box shown at150 in FIGURE 1. The apparatus 170 in its preferred form comprises `asuction tube 172 connected to a vacuum source and having an inletdefined by the longitudinal edges of a pair of plates 174 and 176 whichextend the length of the suction forming roll 10 and project downwardlyinto very close proximity to the inside surface of the wire 82.Accordingly, water is drawn up from the top or felt side of the paperweb through the endless wire 82 and into the inlet between the edges ofthe two plates 174 and 176. In addition, the forward plate member 176acts as a scraper and scoops up water from the top of the wire, thewater then being discharged via a guide member 178 into a drainage panor trough 180. Thus, the suction tube assembly may be mounted at theunderside of the frame element 72 in place of the vacuum box 150, andsuch assembly will draw off water from the top side of the web by eitheror both of a suction action and the scooping effect of the forward platemember 176. A second suction tube assembly 170 which is substantiallyidentical to the assembly 170 described hereinabove may if desired bemounted immediately adjacent the unit 170 as shown in FIGURE 2. In someapplications it may be desirable to utilize foils above the moving topwire 82 in place of the suction doctors described hereinabove.

One of the important advantages of the paper-forming apparatus describedherein is that it substantially eliminates the problem heretoforecreated due to the extremely small clearance required between the wiresurface of the forming roll 10 and the tip of the upper nozzle lip 48a.That is, the clearance between the forming roll wire surface 18 and theend of the metal nozzle lip 48a has heretofore been in the approximaterange of 0.010 inch to 0.040 inch, it being necessary to have the tip ofthe top lip in such close proximity to the forming roll in order tomaintain the stock under complete control until the sheet is formed orset. However, with such small clearances solid particles would tend tocatch under the nozzle lip and cause damage to the paper web and/or thewire surface 18. In accordance with the present invention, the upper lip48a of the nozzle is relatively short and does not run as close to thewire surface 18 of the forming roll 10, and the control over the stockheretofore afforded by the long end of the upper lip is now provided bythe moving stock control member or endless wire 82 which moves atapproximately the peripheral speed of the forming roll 10 and canaccommodate solid particles without causing any damage.

While the left hand wire turning roll member 120 may be in closeproximity to the forming roll wire surface 18, the roll is covered witha soft cellular vor porous cover which positions the endless wire 82 butis sufliciently resilient to permit local indentation when a foreignobject passes beneath it. The wire turning roll 120 may comprise a metalroll which is covered with a layer of resilient rubber over which isattached a honeycomb rubber structure, or in the alternative the roll120 may constitute a metal roll which is jacketed with a syntheticsponge material having an open pore structure. The right hand wireturning or support roll 122 is positioned adjacent the nozzle upper lip48a so as to train the endless wire 82 in such a way that it becomes anapproximate continuation of the top lip profile. The latter roll 122 mayconstitute -a solid metal roll member, or if desired it may be providedwith a rubber cover or the like. The endless top wire or fabric 82constitutes a stock control member and serves to maintain the stockunder control after it leaves the nozzle and until it has been formed orset. The movable stock control member 82 may be made from conventionalFourdrinier wire, or if desired it may be made from various types ofporous fabric, for example a synthetic fiber fabric.

Where the movable stock control member 82 is used in combination withthe nozzle upper lip 48a in accordance with the present invention, thetip of the upper nozzle lip may be spaced from the forming drum wiresurface 18 by at least approximately 0.040 inch, and in manyapplications clearances of 0.060 inch or greater will be quitesatisfactory. The clearance between the tip of the bottom lip S0 and theforming roll wire surface 18 may be in the approximate range of 0.010inch to 0.030 inch. The length of the upper lip section 48a may beapproximately l2 inches or less, and in many applications optimumresults may be achieved where the upper lip section 48a is onlyapproximately 4 inches or less in length.

It has been found that the apparatus described hereinabove, includingthe moving top Wire or stock control member which engages or wraps on asegment of the forming roll periphery and moves at the approximate speedof the latter, is highly effective as a high speed publication sheetforming device, and is particularly useful in the production oflightweight publication grades of book paper. It can produce merchantgrades of book paper of excellent quality at unusually high speeds andwith greater forming consistencies. In particular, speeds well in excessof 2000 feet per minute are possible with the sheet forming apparatus ofthe present invention. One of the principal reasons for the higherspeeds which can be achieved is due to the use of the moving top wire orfabric 82 which in effect replaces the end of the upper nozzle lip andthereby permits use of a shorter upper lip member which need not extendas close to the forming drum wire surface as would otherwise benecessary. As speed is increased, the drainage effect of the top wire 82on the forming sheet effects improved water removal, thereby maintainingthe required pick-up consistencies at the pick up point with higherspeed operation. Moreover, one of the principal advantages of the movingtop wire or stock control is its action in freezing the forming sheetstructure in opposition to the centrifugal force which tends to lift itfrom the forming roll wire surface 18.

With respect to dewatering of the stock, the stock suspension deliveredby the nozzle 42 may for example constitute approximately 1% solids,whereas the stock must be dewatered to approximately 15% solids by thetime the web reaches the pick-up roll 146. Accordingly, if it be assumedthat the apparatus is running at approximately 1900 feet per minute,then in the embodiment being described the sheet must be dewatered from1% solids to 15% solids in less than 0.13 second, which is roughlyequivalent to removing 43 gallons per minute per square foot of formingsurface. Another of the important advantages of the sheet formingapparatus of the present invention is that it permits a certain amountof dewatering to be accomplished from the top side or felt side of theweb between the two guide rolls 120 and 122, such dewatering beingeffected through the moving stock control member 82 which comprises aporous member fabricated from Fourdrinier wire or a porous fabric or thelike. Consequently, it is possible to accomplish more complete fixing ofthe newly formed web than would otherwise be possible in the same lengthof time.

It is believed that at the lip clearances described herein, and whenoperating at high speed and consistency, the lip profile and itssettings are less significant than satisfying the requirements of (a)minimum drag on the web as it leaves the pressure forming area, and (b)dewatering rates such as to avoid creating a partial vacuum under thelip. Both of these factors favor a short upper nozzle lip 48a and arebelieved to partially account for the success of the present system. Oneof the purposes of a short top lip is to provide high pressures underthe lip without effecting excessive drainage, since high pressures underthe top lip section are desirable for good formation of the web.Pressures of 2 to 3 p.s.i. have worked satisfactorily, but in manyapplications it may be desired to provide higher pressures in the rangeof to 6 p.s.i. in order to achieve higher formation levels.

The foregoing sheet forming apparatus is not only relatively simple andinexpensive, but it results in a highly improved method for themanufacture of lightweight publication and other types of paper havingincreased uniformity, both in the machine and cross direction, as wellas more equalized wire and felt side properties. It is possible withsuch apparatus to maintain the stock under complete control until thesheet is formed or set, and yet it eliminates the problems which wouldotherwise be encountered if it was necessary to provide a long uppernozzle lip which extends in very close proximity to the forming rollwire surface.

I claim:

1. In a paper making machine, in combination, a suction forming roll, astock nozzle extending to the periphery of the roll for delivery ofstock suspension thereto, said nozzle comprising an upper lip member anda lower lip member, said upper lip member extending substantially beyondsaid lower lip member in closely spaced relationship to the suctionforming roll periphery to dene a rst forming zone, and said upper lipmember being arcuate so as to conform to the configuration of saidsuction forming roll, a stock control member disposed immediatelyadjacent the tip of the upper lip member in wrapped relation to asegment of the suction forming roll periphery so as to functionsubstantially as a. continuation of said upper lip member and therebydefine a second forming zone, said stock control member comprising anendless exible member which is perforate and accommodates dewatering ofthe stock therethrough, guide means for supporting said stock controlmember and for maintaining an operative portion of its length in wrappedengagement with a segment of the periphery of said rotatable formingroll, pick-up means spaced circumferentially' from said stock nozzle onthe opposite side of said stock control member for removing theresulting web from said forming roll, and drive means for continuouslymoving said stock control member in the same direction as said rollperiphery.

2. The device of claim 1 in combination with water removal means,operatively associated with said endless exible member at the sidethereof opposite the roll.

3. In a cy-linder-type device for forming a continuous paper web, incombination, a rotatable suction forming roll, nozzle means arranged inclose proximity to said forming roll for delivery of stock suspension toa forming area on the periphery thereof, the nozzle means comprising anupper lip member and a llower lip member, said upper lip memberextending substantially beyond said lower lip member and in closelyspaced relationship to the suction forming roll periphery to dene afirst forming zone, and said upper lip member being arcuate so as toconform to the configuration of said suction forming roll, pick-up meanscircumferentially spaced from said nozzle means for removing theresulting web from said forming roll, an endless stock control membermade of a liexible material and having a width approximately equal tothe width of said nozzle means, said stock control member being disposedimmediately adjacent the tip of said upper nozzle lip member so as tofunction substantially as a continuation of said upper nozzle lipmember, guide means for supporting said stock control member and formaintaining an operative portion of its length in wrapped engagementwith a segment of the periphery of said rotatable forming roll betweensaid nozzle means and said pick-up means to dene a second forming zone,and drive means for effecting continuous movement of said stock controlmember about said guide means and in the same direction of movement asthe peripheral segment of said rotatable forming roll with which it isengaged, whereby said stock control members serves to control said stockand apply pressure thereto thereby assisting in the formation of saidweb after the stock has passed beyond the control of said upper nozzlelip member and before the web is removed by said pick-up means.

4. In a cylinder-type device for forming a continuous paper web, incombination, a rotatable suction forming roll, nozzle means arranged inclose proximity to said forming roll for delivering stock suspension toa forming area on the periphery thereof, the nozzle means comprising anupper lip member and a lower lip member, said upper lip member extendingsubstantially beyond said lower lip member and in closely spacedrelationship to the suction forming roll periphery to define a iirstforming zone, and said upper lip member being arcuate so as to conformto the configuration of said suction forming roll, pick-up meanscircumferentially spaced from said nozzle means for removing theresulting web from said forming roll; an endless stock control membermade of a flexible material and having a width approximately equal tothe width of said nozzle means, said stock control member disposedimmediately adjacent the tip of said upper nozzle lip member so as tofunction substantially as a continuation of said upper nozzle lipmember, support means for supporting said stock control member and formaintaining an operative portion of its length in wrapped engagementwith a segment of the periphery of said rotatable forming roll betweensaid nozzle means and said pick-up means to dene a second forming zone,said support means including a first rotatable support roll positionedin close proximity to the periphery of said forming roll and to the tipof said upper nozzle lip member and a second rotatable support rollpositioned in close proximity to the periphery of said forming rollintermediate said first support roll and said pick-up means, saidendless stock control member being trained over said first and secondsupport rolls and thereby held in partially wrapped engagement with saidsegment of the periphery of said forming roll, and drive means foreffecting continuous movement of said stock control member about saidsupport means and in the same direction of movement as the peripheralsegment of said rotatable forming roll with which it is engaged, wherebysaid stock control member serves to control said stock and applypressure thereto thereby 'assisting in the formation of said web afterthe stock has passed beyond the control of said upper nozzle lip memberand before the web is removed by said pick-up means.

5. The device of claim 4 including an upper nozzle lip member which isformed with an arcuate upper surface at its tip so as to conformapproximately to the configuration of said first support roll.

6. The device of claim 4 wherein said second support roll is providedwith a soft outer cover which is suiciently resilient to permit localindentation when a foreign object passes beneath it.

7. The device of claim 1 wherein said soft outer cover is made of aporous material.

8. The device of claim 4 including means for adjusting the positions ofsaid first and second supoprt rolls to permit variable pressing of thepaper web between the stock control member and the periphery of theforming roll.

9. In a cylinder-type device for forming a continuous paper web, incombination, a rotatable suction forming roll, nozzle means arranged inclose proximity to the forming roll for delivering stock suspension to aforming area on the periphery thereof, the nozzle means comprising anupper lip member and a lower lip mem-ber, said upper lip memberextending substantially beyond said lower lip member and in closelyspaced relationship to the suction forming roll periphery to define afirst forming zone, and said upper lip member being arcuate so as toconform to the configuration of said suction forming roll, pick-up meanscircumferentially spaced from said nozzle means for removing theresulting web from the forming roll, an endless stock control membermade of a flexible material and having a Width approximately equal tothe width of said nozzle means, said stock control member being disposedimmediately adjacent the tip of the upper nozzle lip member so as tofunction substantially as a continuation of said upper lip member anddefine a second forming zone, support means for supporting said stockcontrol member and for maintaining an operative portion of its length inwrapped engagement with a segment of the periphery of said rotatableforming roll between said nozzle means and said pickup means, drivemeans for effecting continuous movement of said stock control memberabout said support means and in the same direction of movement as .theperipheral segment of said rotatable forming roll with which it isengaged whereby said stock control member serves to control said stockand apply pressure thereto thereby assisting in the formation of saidweb after the stock has passed beyond the control of said upper nozzlelip member and before the web is removed by said pick-up means, andmeans for removing water from the top side of said web, said waterremoval means being located Iimmediately above that portion of the stockcontrol member which is in engagement with said forming roll.

10. The device of claim 9 wherein said water removal means comprises avacuum box.

11. The device of claim 9 wherein said Water removal means comprises asuction tube having scraper scoop means associated therewith.

12. In a cylinder-type device for forming a continuous paper web, incombination, a rotatable suction forming roll, nozzle means arranged inclose proximity to said forming roll for delivering stock suspension toa forming area on the periphery thereof, the nozzle means comprising anupper lip member and a lower lip member, said upper lip member extendingsubstantially beyond said lower lip member and in closely spacedrelationship to the suction forming roll periphery to define a firstforming zone, and said upper lip member being arcuate so as to conformto the configuration of said suction forming roll, pick-up meanscircumferentially spaced from said nozzle means for removing theresulting web from said forming roll, an endless stock control membermade of a flexible porous material kand having a width approximatelyequal to the width of said nozzle means, said stock control memberdisposed immediately adjacent the tip of the upper nozzle lip member soas to function substantially as a continuation of said upper nozzle lipmember; support means for supporting said stock control member and formaintaining kan operative portion of its length in wrapped engagementwith a segment of the periphery of said rotatable forming roll betweensaid nozzle means and said pick-up means, said support means including afirst rotatable support roll positioned in close proximity to theperiphery of said forming roll and to said tip of the upper nozzle lipmember land a second rotatable support roll positioned in closeproximity to the periphery of said forming roll intermediate said firstsupport roll :and said pick-up means, said endless stock control memberbeing trained over said first and second support rolls and thereby heldin partially wrapped engagement with said segment of the periphery ofsaid forming roll, drive means for effecting continuous movement of saidstock control member labout said support means in the same direction ofmovement as the peripheral segment of said rotatable forming roll withwhich it is engaged and at approximately the peripheral speed of thelatter whereby Said stock control member serves to control said stockand apply pressure thereto thereby assisting in the formation of saidweb after the stock has passed beyond the control of said upper nozzlelip member and before the web is removed by said pick-up means, andmeans for removing water from the top side of said web, said waterremoval means being located between said first and second support rollsand immediately above that portion of the stock colntrol member which isin engagement with said forming ro l.

References Cited UNITED STATES PATENTS 2,911,039 11/1959 Hornbostel etal. 162-369 XR 3,321,360 `5/1967 Holt 162--317 XR 3,056,719 11/1962Webster 162-212 XR S. LEON BASHORLE, Primary Examiner R. H. TUSHIN,Assistant 4Examiner U.S. Cl. X.R. 162-210, 214, 217, 318, 344, 364

